Apparatus for making artificial branches, brushes, and the like

ABSTRACT

Apparatus for making artificial branches, brushes, etc., from a plurality of filaments held between a pair of twisted wires. Comprises a picker device, the peripheral surface of which is advanceable in a predetermined direction. The picker device is adapted to pick up and contain a plurality of separate bundles of filaments, the filaments being disposed transversely of the direction of movement of the surface. The peripheral surface has a continuous slot or space therein, this slot being parallel to the direction of advancement of the peripheral surface. The slot or space is adapted to receive the lower of the pair of wires, which wire extends outwardly from the exit end of the peripheral surface under the filaments. The apparatus further comprises means for feeding a plurality of filaments to the picker device, drive means for advancing the peripheral surface, means for guiding the second or upper wire into position above the lower wire at the exit end of the picker device, independent drive means for advancing these wires, and means for twisting the wires together.

[451 Feb. 12, 1974 APPARATUS FOR MAKING ARTIFICIAL BRANCHES, BRUSHES, AND THE LXKE ABSTRACT Apparatus for making artificial branches, brushes, etc., from a plurality of filaments held between a pair [75] Inventor: Robert Barrett, Beacon, NY.

[73] Assigneez Gordon Industries, he Newburgh, of twisted wires. Comprises a picker device, the peripheral surface of which is advanceable in a predetermined direction. The picker device is adapted to pick [22] Filed: Aug. 7, 1972 up and contain a plurality of separate bundles of filaments, the filaments being disposed transversely of the direction of movement of the surface. The peripheral surface has a continuous slot or space therein, this slot being parallel tothe direction of advancement of the peripheral surface. The slot or space is adapted to re- Appl. No.: 278,397

ceive the lower of the pair of wires, which wire ex- 202 /0/ 0/0 070 3. 3 91. 6, 181 W n 4 b l l I ll] 218 555 ill.

1 tends outwardly from the exit end of the peripheral [56] Referen s Cit d surface under the filaments. The apparatus further UNITED STATES PATENTS comprises means for feeding a plurality of filaments to Marks ct alwulmn the picker device, drive means for advancing the peripheral surface, means for guiding the second or upper wire into position above the lower wire at the 3,376,073 4/1968 3,596,998 8/1971 Romanowski et al. 3,160,440 12/1964 Gelardi exit end of the picker device, independent drive means for advancing these wires, andrneans for twisting the wires together.

Attorney, Agent, or Firm Hubbell Myron Cohen et al.

7 Claims, 1 Drawing Figure PAIENTEDFEBIBIBH 3.791.421.

RECIPRO CATING MEANS APPARATUS FOR MAKING ARTIFICIAL BRANCHES, BRUSHES, AND THE LIKE BACKGROUND OF THE INVENTION 1. Field of the Invention This invention relates to an apparatus for making artificial branches, e.g., for use in artificial trees such as Christmas trees, brushes, or the like, from a plurality of filaments. The apparatus of this invention provides a simple means for controlling or varying the density of the bristles along the length of the branch or brush.

2. Description of the Prior Art Apparatus for making artificial branchesybrushes, and like articles are well known. In prior art apparatus for making artificial branches, e.g., for artificial Christmas trees, the needle-like filaments or bristles, generally of plastic material, are conventionally disposed in a hopper and are biased, either by gravity or by a weight or spring, toward a rotating wheel having a transversely slotted periphery and known in the art as a picker wheel. As each slot or groove comes by the hopper a quantity of filaments moves into the slot, which pulls them away from the hopper and feeds them between two vertically spaced wires. The wires are subsequently twisted to hold the filaments in place and thereby form a bristle-containing branch. One of the wires commonly runs in a groove in the picker wheel, so as to position the wire directly beneath the filaments which have been picked up by the picker wheel. The

wire thereby provides support for the filaments when,

the filaments move tangentially away from the picker whell.

The foregoing arrangement gives rise to difficulties when it is desired to have portions of the branch without bristles, or to vary the density of the bristles, that is, the number of bristles per unit length of wire. These difficulties arise from the fact that the wire moves longitudinally at the same linear speed as the periphery of the picker wheel in which it rides. Thus, the only presently known manner of providing blank or bristleless portions of a branch is by a relatively complex movable mechanical means which overlies the hopper opening to prevent filaments from being fed into the picker wheel slots. Such an approach is relatively expensive and has not been altogether satisfactory. There is no known way of providing continuous variation of bristle density;

SUMMARY OF THE INVENTION The present invention provides an apparatus for making artificial branches, brushes, or the like. This apparatus comprises a picker device, the peripheral surface of which is advanceable in a predetermined direction, the picker device being adapted to pick up and retain a plurality of bundles of filaments in an orientation transverse to the direction of advancement of the pe-- ripheral surface. The picker device is provided with a space or slot therein, this slot extending in the direction of advancement and adapted to receiver a wire therein, with the wire extending outwardly from the exit end of the picker device. Means are provided for feeding a plurality of filaments to the picker device, and first drive means are provided for advancing the peripheral surface in the predetermined direction. As the filaments are advanced to the exit end of the picker device the wire, which is disposed beneath the filaments, will support them. Means are provided for guiding a second wire into a position whereby it is disposed above the exit end of the first wire. Second drive means are provided for moving the wires in the same direction as the predetermined direction ofmovement of the filaments, the second drive means being independent of the first drivemeans. The apparatus further includes means for twisting the wires together so as to fix the bristle bundles therebetween.

Cutting means are provided to cut the bristlecontaining twisted strands, to thereby obtain the branch, brush, or the like.

Inasmuch as the rate of travel of the wires is independent of the rate of travel of the filaments on the pick, the density of the bristles along the wires, i.e., the number of bristles per unit length of wires, is readily controlled by regulating the linear speed of either the wires or the peripheral surface of the picker device, preferably the latter.

BRIEF DESCRIPTION OF THE DRAWING The invention will be best understood from the following detailed description, taken in conjunction with the accompanying drawing, which is a perspective view of the apparatus of my invention.

DESCRIPTION OF THE PREFERRED EMBODIMENT Referring to the drawing, the apparatus for making artificial branches, brushes, or the like 'is generally designated by the reference numeral 10. The apparatus comprises a picker device 12, a hopper 14 for introducing a plurality of filaments to the picker device, drive means 16 for advancing the peripheral surface of the picker device in a predetermined direction, and means 18 for advancing a pair of wire strands in the direction of movement of the peripheral surface of the picker device and for twisting such strands.

Referring to the picker device 12, this device is made up of a plurality of belts 20, 22, 24 and 26. Each of these belts is similar in structure to a conventional timing belt. Thus, each belt is provided with a plurality of equally spaced transverse channels or slots 28. The belts are disposed about a pair of rollers 30, 32, one of which, roller 30, is an idler roller, the other of which, roller 32, is motor driven by a variable speed motor 33. Means are provided for'adjusting the tension on the belts, these means being schematically. illustrated by screws 34. i

Belts 20, 22, 24, 26 are disposed parallel to and in transverse alignment with one another such that the slots 28 of each belt are in registry with corresponding slots 28 in the other belts. By virtue of this arrangement the belts cooperate to form transverse slots substantially the length of rollers 30, 32 each of these slots being adapted to receive a plurality of filaments. The upper surfaces 36 of each belt are substantially coplanar.

A hopper 14 is disposed above the picker device, with the bottom of the hopper being in close proximity to and substantially co-planar with the upper surfaces 36 of the belts. A plurality of filaments 37 are disposed in the hopper so as to be gravity fed to the transverse slots 28 of the picker device.

Filaments 37, which subsequently form the bristles of the desired artificial branch, brush, or the like, may be made of any suitable material. Thus, natural materials,

such as horse hair or the like, or synthetic materials, such as a thermoplastic, e.g., polypropylene, polyethylene, polystyrene, polyvinyl chloride, or the like, may be employed.

Between belts 20, 22, 24, and 26 are longitudinal slots or spaces 38, 40, and 42, respectively. Downstream of the hopper 14 there are mounted in spaces 38 and 42 adjustable L-shaped members (skivers) 44 and 46, respectively. The bottom surface of each skiver is desirably substantially co-planar with the upper surfaces 36 of the belts. As the filaments 37 advance in slots 28 beyond the hopper 14, the skivers 44 and 46 serve to retain the filaments in the slots.

Guide rollers 48 and 50 are mounted above rollers 30 and 32, respectively, each of these guide rollers being maintained close to or preferably in contact with belts 20, 22, 24 and 26. Guide roller 48 is provided with a central circumferential groove 52, which groove is in vertical alignment with central longitudinal space 40.

Extending longitudinally in space 40 between belts 22 and 24 is a strand 56, which strand desirably is a wire, stored on feed reel 57. Strand 46 is disposed such that it is either co-planar with or slightly below the bottom surface of channels 28, whereby the strand will be beneath the filaments 37 that are deposited in the channels from the hopper.

A second strand 58, which also preferably is a wire, extends vertically downwardly from feed reel 59 into groove 52, about 90 of roller 48 within groove 52, and then horizontally outward from roller 48 in vertically spaced parallel relation above strand 56, so as to sandwich a bundle of filaments 37 between the strands 56, 58,.

Referring to means 18 for advancing wires 56 and 58 and twisting them, there is shown a conventional chuck 62, the three jaws 64 of which can be adjusted to tightly grasp strands 56and 58. Motor means 66 are provided for rotating chuck 62 to thereby twist strands 56 and 58 together so as to firmly fix and lock the bundles 60 of filaments therebetween, thereby forming bristles.

Means 18 further comprises means 68 for longitudinally advancing chuck 62 along rods 69 in the same direction as the direction of longitudinal movement of the top side of belts 20, 22, 24 and 26. The particular type of chuck advancing means employed is also not critical. For instance, such means may be of the type described in U.S. Pat. No. 2,742,327.

The twisting of strands 56, 58 and their longitudinal advancement are preferably simultaneous. After the twisting, the wires are cut, as by cutter 70. A suitable cutting device is described in said U.S. Pat. No. 2,742,327. The cutting desirably takes place preferably just to the left of rollers 48 and 30, as viewed in the drawing, to thereby obtain the desired artificial branch, brush, or the like, and the operation is then repeated.

Inasmuch as the rate of advancement of the wire strands 56 and 58 is entirely independent of the rate of advancement of the upper peripheral surface of the picker device, this enables one to easily control the density of the bristles per unit length of strand. That is to say, the greater the relative speed of the strands with respect to the upper peripheral surface of the picker device, the lower the number of bundles of filaments.

per unit length of strand, and the lower the bristle density per unit length. For a greater density, the relative speed is simply decreased, e.g., by adjusting the means 68 for advancing the strands so as to reduce their rate of advancement to whatever speed is desired. Moreover, by interrupting movement of belts 20-26, a portion of the branch can be made without bristles, which may be highly desirable in the formation of composite branches or trees.

While the foregoing description has been with reference to four belts 20, 22,24 and 26, the apparatus of my invention may, of course, instead comprise either more or less than four belts. Thus, it is apparent that a pair of belts can be employed, these belts being in par allel spaced orientation to define a longitudinal space therebetween and being in transverse alignment whereby the slots in the belts are in registry with one another. A longitudinal strand is disposed in the longitudinal space so as to be disposed beneath and in supporting relation with the bristles in the slots. Likewise, a single belt such as a timing belt may be employed, this belt being provided with a continuous longitudinal groove or slot therein, with the lower wire 56 being disposed in such groove beneath the bristles. Thus, it is to be understood that when reference is made in this specification and claims to a flexible continuous belt having a continuous longitudinal space therein, this expression is intended to include both a single belt and a plurality of belts.

While I have herein shown and described the preferred embodiment of my invention and have suggested modifications therein, other changes and modifications may be made therein within the scope of the appended claims without departing from the spirit and scope of this invention.

Having thus described my invention, what is desired to be secured by Letters Patent and hereby claimed is:

1. Apparatus for making artificial branches or brushes from a plurality of filaments, this apparatus comprising:

a picker device comprising a flexible endless belt having an upper and a lower reach and being advanceable in a predetermined direction, said end less belt further having a continuous longitudinal space extending in the direction of advancement of said belt for receiving a first strand therein, said belt further having a plurality of spaced apart transverse slots for receiving bundles of filaments therein;

a hopper for containing filaments oriented parallel to said transverse slots and having an open lower end in close confronting rerelation to the upper reach of said belt for feedingbundles of filaments to said transverse slots; I 7

means for supplying said first strand in a path extending through a preselected portion of said continuous space in the upper reach of said belt and thence away from said belt;

first drive means for advancing said belt in said predetermined direction;

means for supplying and guiding a second strand to a position above and in spaced parallel relation with the portion of said first strand thatis away from said belt;

second drive means for moving said strands in the direction of advancement of said upper reach of said belt; and

means for twisting said strands together.

2. The apparatus of claim 1, said apparatus additionally comprising means for retaining said filaments in said transverse slots prior to the twisting of said strands.

3. The apparatus of claim 1 wherein said endless belt comprises a pair of endless belts, said belts being parallel to and spaced from one another to thereby define said continuous longitudinal space, the transverse spaced slots of each of said belts being in registry with one another.

4. The apparatus of claim 1, said apparatus further comprising means for varying the relative rate of movement between said belt and said strands.

5. The apparatus of claim 4 wherein said means for varying the relative rate of movement is a means for varying said relative rate to any value within a continuum between zero and a predetermined maximum. 

1. Apparatus for making artificial branches or brushes from a plurality of filaments, this apparatus comprising: a picker device comprising a flexible endless belt having an upper and a lower reach and being advanceable in a predetermined direction, said endless belt further having a continuous longitudinal space extending in the direction of advancement of said belt for receiving a first strand therein, said belt further having a plurality of spaced apart transverse slots for receiving bundles of filaments therein; a hopper for containing filaments oriented parallel to said transverse slots and having an open lower end in close confronting rerelation to the upper reach of said belt for feeding bundles of filaments to said transverse slots; means for supplying said first strand in a path extending through a preselected portion of said continuous space in the upper reach of said belt and thence away from said belt; first drive means for advancing said belt in said predetermined direction; means for supplying and guiding a second strand to a position above and in spaced parallel relation with the portion of said first strand that is away from said belt; second drive means for moving said strands in the direction of advancement of said upper reach of said belt; and means for twisting said strands together.
 2. The apparatus of claim 1, said apparatus additionally comprising means for retaining said filaments in said transverse slots prior to the twisting of said strands.
 3. The apparatus of claim 1 wherein said endless belt comprises a pair of endless belts, said belts being parallel to and spaced from one another to thereby define said continuous longitudinal space, the transverse spaced slots of each of said belts being in registry with one another.
 4. The apparatus of claim 1, said apparatus further comprising means for varying the relative rate of movement between said belt and said strands.
 5. The apparatus of claim 4 wherein said means for varying the relative rate of movement is a means for varying said relative rate to any value within a continuum between zero and a predetermined maximum.
 6. The apparatus of claim 4 wherein said endless belt comprises a pair of endless belts, said belts being parallel to and spaced from one another to thereby define said continuous longitudinal space, the transverse spaced slots of each of said belts being in registry with one another.
 7. The apparatus of claim 6 wherein said means for varying the relative rate of movement is a means for varying said relative rate to any value within a continuum between zero and a predetermined maximum. 